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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
  • C04B35/584—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
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  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
  • B28B7/44—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for treating with gases or degassing, e.g. for de-aerating
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
  • C04B35/584—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
  • C04B35/591—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride obtained by reaction sintering
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/64—Burning or sintering processes
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/64—Burning or sintering processes
  • C04B35/65—Reaction sintering of free metal- or free silicon-containing compositions
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/38—Non-oxide ceramic constituents or additives
  • C04B2235/3817—Carbides
  • C04B2235/3826—Silicon carbides
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/38—Non-oxide ceramic constituents or additives
  • C04B2235/3852—Nitrides, e.g. oxynitrides, carbonitrides, oxycarbonitrides, lithium nitride, magnesium nitride
  • C04B2235/3873—Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
  • C04B2235/428—Silicon
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/46—Gases other than oxygen used as reactant, e.g. nitrogen used to make a nitride phase
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
  • C04B2235/54—Particle size related information
  • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
  • C04B2235/5427—Particle size related information expressed by the size of the particles or aggregates thereof millimeter or submillimeter sized, i.e. larger than 0,1 mm
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
  • C04B2235/54—Particle size related information
  • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
  • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
  • C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
  • C04B2235/6567—Treatment time
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
  • C04B2235/658—Atmosphere during thermal treatment
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
  • C04B2235/94—Products characterised by their shape

Definitions

• the present invention concerns a method for preparing of at least one ceramic shaped part, apparatus for preparing of at least said ceramic shaped part and use thereof.
• Ceramic shaped parts it is a problem today to produce shapes with the requested dimensions, especially large shaped parts, which can be recycled several times. Further, large ceramic shaped parts are required within several fields such as for example preparing of silicon ingots to the solar cell industry.
• Today when preparing silicon ingots for further production of silicon wafers, shaped parts consisting of silica is used. At high temperatures, which are necessary when preparing silicon for solar cell purposes, shaped parts of silica, so-called silica crucibles, is exposed to temperatures up to 1500 °C. Silica crucibles soften at high temperatures such as 1500 0 C. When cooling the silica crucibles to room temperature, crack formation arises which involve no recycling of the crucibles. In several production processes, crucibles which can only be used once, involve a substantial cost.
• a slicker/dispersion which is an aqueous composition of mainly the preferred powder and a suitable binding agent, is prepared.
• the slicker/dispersion can also be based on other liquids than water, such as ethanol and other alcohols.
• the slicker is poured into a casting mould (typical a plaster mould).
• the liquid of the slicker is extracted in the mould and the mould is dismantled after a while.
• a green body consisting of powder bounded by the binding agent is achieved.
• the green body is then prepared in several processes such as drying, removing of the binding agent and nitriding/sintering, before a desired product is achieved.
• the green body has low strength and thus can easily change shape and crack in further processing and handling. This is more critical when lager and more complicated shaped parts are prepared.
• Pressure casting is another known technique.
• the basis is mainly a composition of powder, binding agent and some liquid.
• the composition is compressed by different methods to the desired shape, a green body. Compression of big and or complicated geometries are very difficult and today not solved technically.
• the green body possesses the same problems as mentioned above.
• an object of the invention is to provide a method well suitable for preparing ceramic shaped parts for use when preparing silicon ingots for the solar cell industry. Further, it is an object of the present invention to provide a method in which said ceramic shaped part can be recycled several times. Problems such as deforming and cracking of the prepared ceramic shaped part are avoided in the present invention. Further, no binding agent or liquid is used in the present invention, and thus there is no need for an extra process step to dry and remove the binding agent. It is also used a shape which equalizes the temperature of the ceramic shaped part during the nitriding process which by that means will minimize the probability of forming liquid silicon. Compared with prior art in the field the present invention represents a method which is simplified, which is suitable for preparing of large shaped parts, which consist of fewer process steps, which avoid deformation and which is economical favourable.
• the present invention provides a method for preparing of at least one ceramic shaped part, wherein
• a cavity is provided between at least one external shape and at least one internal shape
• the Si-powder composition is heated in a reactive gas atmosphere to a temperature in which a reaction bounded ceramic shaped part is obtained.
• a reaction bounded ceramic shaped part is obtained.
• at least one of the external shapes are perforated and also at least one of the internal shapes are perforated. Perforated shapes result in a relatively uniform reactive gas atmosphere. Further, the reaction for preparing of the reaction bonded ceramic shaped part will take place quickly on the basis of the perforated shapes which ensure supply of the desired gas atmosphere.
• the internal shapes according to the invention are separated from each other by inserting of a thermal resistant deformable material in which the thermal resistant deformable material is chosen from graphite felt, graphite wool or graphite bar.
• the cavity provided between at least the external- and internal shape as mentioned above is coated with a slurry prior to providing the cavity.
• a foil is applied according to the invention between at least one external shape and said slurry prior to coating with the slurry. Further, a foil is applied between at least one internal shape and said slurry prior to coating with the slurry.
• a temperature resistant perforated foil is applied prior to coating with the slurry.
• Said slurry comprises a powder containing silicon nitride of particle size ⁇ 100 ⁇ , ⁇ 80 ⁇ , ⁇ 60 ⁇ , ⁇ 40 ⁇ , ⁇ 20 ⁇ , ⁇ 10 ⁇ , ⁇ 5 ⁇ og ⁇ 1 ⁇ .
• the mentioned Si-containing powder composition according to the present invention is chosen from at least one of the following components: silicon, silicon carbide, silicon nitride.
• the reactive gas atmosphere contains at least nitrogen. Further, other gas atmospheres or gas compositions can be used when the invention is performed.
• At least one external shape and at least one internal shape according to the invention comprise a graphite containing material.
• the present invention comprises an apparatus for preparing at least one ceramic shaped part comprising: at least a cavity between at least one external shape and at least one internal shape, means for inserting of a Si-containing powder composition, means for heating in a reactive gas atmosphere.
• Apparatus according to the invention comprises that at least one of the external- and internal shapes are perforated. Further, it is as mentioned desirable to provide apparatus which can be exposed to thermal stress and at the same time maintain the original dimensions and also avoid crack formation.
• the present invention comprises apparatus as described in the preceding where at least the internal shape possess a thermal expansion coefficient which is higher than the thermal expansion coefficient of a reaction bounded ceramic shaped part, and at least the external shape possess a thermal expansion coefficient lower than of the reaction bounded ceramic shaped part.
• a thermal resistant deformable material separate at least two internal shapes.
• the thermal resistant deformable material is chosen from graphite felt, graphite wool or graphite bar.
• the present invention comprises use of a cavity provided between at least one external shape and at least one internal shape, wherein a Si-containing powder composition is provided in the cavity previous of heating the powder composition in a reactive gas atmosphere to a temperature in which a ceramic shaped part is prepared. Said cavity is coated with a silicon nitride containing slurry prior to providing the cavity. A foil is used between at least one external shape and said slurry prior to coating with the slurry. Further, a foil is used between at least one internal shape and said slurry prior to coating with the slurry. The foil consists of a temperature resistant perforated foil.
• the use of the present invention takes place in a gas atmosphere comprising nitrogen or a nitrogen containing gas atmosphere. Description of the figures.
• the shaping of at least one ceramic shaped part depends on the object and the use of the ceramic shaped part. In preparing of silicon ingots to the solar cell industry the shaping will often be in the form of square or rectangular shaped parts.
• Figure 1 shows a cross-section of composed shape of different parts.
• figure 2 a cross-section seen from the side of a square shape is shown.
• Figur 3 shows a cross-section of a square shape seen from above.
• Figures 4 and 6 respectively show a circular internal shape and also a circular complete shape seen from above.
• Figures 5 and 7 shows a cross-section of a circular internal and external shape.
• a shape composed of different parts of graphite containing material was used in the example.
• the shape consisted of an internal shape (A), an external shape (B) 1 a basis plate (bottomplate) (C) and a plate (D) as shown in figure 1.
• the graphite containing parts was perforated, except the basis plate.
• the internal shape comprising four relatively similar graphite containing parts were fastened to each other and to the basis plate. Said parts were fastened to each other with suitable fixing devices in the form of i.a. screws.
• a thermal resistant deformable material (E) in the form of graphite bar graphite felt or graphite wool were applied.
• Perforated graphite foil was applied at the internal graphite containing shapes.
• the perforations of the foil shall preferably not coincide with the perforations of the graphite containing parts.
• the external shapes consisted of four relatively similar graphite containing plates. Perforated graphite foil was applied at the external graphite containing shapes. The surfaces coated with graphite foil were further coated with a silicon nitride containing slurry. The slurry dried at room temperature. The external graphite containing shapes was assembled at the basis plate (figure 1). Further, said external graphite containing parts were fastened above the internal shape and to the basis plate.
• Silicon containing powder with the preferred size within one or several ranges is as follows: ⁇ 10 micron, ⁇ 20 micron, ⁇ 40 micron, ⁇ 60 micron, ⁇ 75 micron, ⁇ 100 micron, ⁇ 120 micron, ⁇ 150 micron, ⁇ 180 micron, ⁇ 200 micron, was placed in the provided cavity (figure 1 , F) between the internal- and external shape. Further, the silicon containing powder was compacted by vibration. Silicon containing powder in the size ranges as described above were in the end placed in the upper area of said cavity. The powder was further compacted by vibration and mechanical compaction. The shapes mounted rigidly were in this example turned around 180 degrees as shown in figure 1. Further the basis plate was disassembled.
• the shapes mounted rigidly were placed in a furnace with nitrogen atmosphere.
• the furnace was quickly heated up to 1100-1200 0 C, and further slowly heated to 1400- 1500 0 C during 40-60 hours.
• the shapes mounted were then cooled down to room temperature.
• the whole furnace cycle i.e. heating, preparing of at least one ceramic shaped part and cooling down
• the external- and internal graphite containing shapes were disassembled, and a reaction bounded silicon nitride shaped part/ceramic shaped part with the same dimension as the cavity between the external- and internal graphite containing shapes were provided.
• Possible remaning slurry from the graphite containing shapes at the ceramic shaped part can in a simple manner be removed with dry ice blasting (t ⁇ rrisblasing) or mechanical rubbing /finishing.
• the graphite containing parts was cleaned with a cleaning cloth and were then ready for re-use.
• example 2 the same procedure as in example 1 was used with exception of the powder composition.
• a powder composition comprising silicon (70 weight%, ⁇ 150 micron) and silicon carbide (30 weight%, ⁇ 150 micron) was used. After disassembling of the graphitic parts, a nitride bounded silicon carbide-shaped part was provided.
• Example 3 I example 3 the method as described in example 1 was used with the exception of the powder composition.
• a powder composition comprising silicon (70 weight%, ⁇ 150 micron) and silicon nitride (30 weight%, ⁇ 10 micron) were chosen. After disassembling of the graphite containing parts, a nitride bounded silicon nitride-shaped part was provided.

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• Chemical & Material Sciences (AREA)
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• Ceramic Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Structural Engineering (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
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• Compositions Of Oxide Ceramics (AREA)
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• 2009
  • 2009-04-23 NO NO20091622A patent/NO334256B1/no not_active IP Right Cessation
• 2010
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  • 2010-04-23 JP JP2012507175A patent/JP2012524706A/ja active Pending
  • 2010-04-23 CN CN201080018032.4A patent/CN102482166B/zh not_active Expired - Fee Related
  • 2010-04-23 US US13/263,973 patent/US20120056359A1/en not_active Abandoned
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